Tailorable polyorbital-hybrid ceramics

ABSTRACT

In an embodiment, a method includes producing a mixed feedstock of at least three halogenated monomer feedstocks. A first of the at least three halogenated monomer feedstocks includes an SP3 carbon, a second of the at least three halogenated monomer feedstocks includes an SP2 carbon, and a third of the at least three halogenated monomer feedstocks includes at least two SP1 carbons. The method further includes producing a polyorbital-hybrid pre-ceramic polymer comprising the SP1 carbons, the SP2 carbon, and the SP3 carbon. The polyorbital-hybrid pre-ceramic polymer is produced by reducing the mixed feedstock such that one or more halogen atoms are removed from the mixed feedstock. The method also includes fabricating the polyorbital-hybrid pre-ceramic polymer into a greenware form and producing a polyorbital-hybrid ceramic carbon comprising the SP1 carbons, the SP2 carbon, and the SP3 carbon. The polyorbital-hybrid ceramic carbon is produced by thermolyzing the polyorbital pre-ceramic polymer.

TECHNICAL FIELD

The present disclosure relates in general to manufacturing ceramics, andmore particularly to manufacturing tailorable polyorbital-hybridceramics.

BACKGROUND

Replacing metal with ceramics in certain applications may providesignificant weight savings. For example, aircraft, spacecraft, andautomobiles all use substantial amounts of metal, thereby increasing theoverall weight of those vehicles. To replace metal with ceramics,though, ceramics need to be produced with certain properties of metals,such as electrical conductivity, ferromagnetism, and good thermalconductivity, in sufficient quantities and in a manner that facilitatesworkability of the ceramic so that the ceramic can be formed intovarious shapes and sizes.

SUMMARY OF EXAMPLE EMBODIMENTS

In an embodiment, a method includes producing a mixed feedstock of atleast three halogenated monomer feedstocks. A first of the at leastthree halogenated monomer feedstocks includes an SP3 carbon, a second ofthe at least three halogenated monomer feedstocks includes an SP2carbon, and a third of the at least three halogenated monomer feedstocksincludes at least two SP1 carbons. The method further includes producinga polyorbital-hybrid pre-ceramic polymer comprising the SP1 carbons, theSP2 carbon, and the SP3 carbon. The polyorbital-hybrid pre-ceramicpolymer is produced by reducing the mixed feedstock such that one ormore halogen atoms are removed from the mixed feedstock. The method alsoincludes fabricating the polyorbital-hybrid pre-ceramic polymer into agreenware form and producing a polyorbital-hybrid ceramic carboncomprising the SP1 carbons, the SP2 carbon, and the SP3 carbon. Thepolyorbital-hybrid ceramic carbon is produced by thermolyzing thepolyorbital pre-ceramic polymer.

In another embodiment, a method includes producing a mixed feedstock ofat least three halogenated monomer feedstocks. A first of the at leastthree halogenated monomer feedstocks includes an SP3 silicon, a secondof the at least three halogenated monomer feedstocks includes an SP2silicon, and a third of the at least three halogenated monomerfeedstocks includes an SP1 silicon. The method further includesproducing a polyorbital-hybrid pre-ceramic polymer comprising the SP1silicon, the SP2 silicon, and the SP3 silicon. The polyorbital-hybridpre-ceramic polymer is produced by reducing the mixed feedstock suchthat a halogen atom is removed from the mixed feedstock. The methodincludes fabricating the polyorbital-hybrid pre-ceramic polymer into agreenware form and producing a polyorbital-hybrid ceramic siliconcomprising the SP1 silicon, the SP2 silicon, and the SP3 silicon. Thepolyorbital-hybrid ceramic silicon is produced by thermolyzing thepolyorbital pre-ceramic polymer.

In another embodiment, a method includes producing a mixed feedstock ofat least four halogenated monomer feedstocks. A first of the at leastfour halogenated monomer feedstocks includes a first SP3 silicon. Asecond of the at least four halogenated monomer feedstocks includes asecond SP3 silicon and one of an SP2 silicon or an SP2 carbon. A thirdof the at least four halogenated monomer feedstocks includes a third SP3silicon and one of an SP1 silicon or at least two SP1 carbons. A fourthof the at least four halogenated monomer feedstocks includes an SP3carbon. The method further includes producing a polyorbital-hybridpre-ceramic polymer that includes at least one of the first SP3 siliconor the SP3 carbon, at least one of the SP2 silicon or the SP2 carbon,and at least one of the SP1 silicon or the at least two SP1 carbons. Thepolyorbital-hybrid pre-ceramic polymer may be produced by reducing themixed feedstock such that a halogen atom may be removed from the mixedfeedstock. The method includes fabricating the polyorbital-hybridpre-ceramic polymer into a greenware form and producing apolyorbital-hybrid ceramic silicon carbide by thermolyzing thepolyorbital pre-ceramic polymer. The polyorbital-hybrid ceramic siliconcarbide may include at least one of the first SP3 silicon or the SP3carbon, at least one of the SP2 silicon or the SP2 carbon, and at leastone of the SP1 silicon or the at least two SP1 carbons.

The present disclosure may provide numerous advantages. For example, themethod of the present disclosure may allow for exploration of the entirehybridization space of carbon-SP1 carbon, SP2 carbon, and SP3 carbonceramics. As another example, the method may allow for tailoring of theamounts of SP1 carbon, SP2 carbon, and SP3 carbon in the final ceramic.As yet another example, the method may produce pre-ceramic polymers thatare workable materials. These workable materials can then be, forexample, dissolved, sprayed, molded, shaped, cast as films, oradditively deposited and built up to produce a greenware item. Becauseof the workability of the materials, the disclosure may provide atechnical advantage of being able to use a tailorable polyhybrid-orbitalceramic to manufacture products that have previously been unable to bemade using Q-carbon, such as, for example, the inductor plates of atransformer or an electric motor.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the disclosed embodiments and theirfeatures and advantages, reference is now made to the followingdescription, taken in conjunction with the accompanying drawings, inwhich:

FIG. 1 is a diagram illustrating an example method of manufacturing atailorable polyorbital-hybrid ceramic carbon, according to an embodimentof the present disclosure;

FIG. 2 is a diagram illustrating an example method of manufacturing atailorable polyorbital-hybrid ceramic silicon, according to anembodiment of the present disclosure;

FIG. 3 is a diagram illustrating an example method of manufacturing atailorable polyorbital-hybrid ceramic silicon carbide, according to anembodiment of the present disclosure; and

FIG. 4 is an exploded view of an example polyorbital-hybrid ceramicstator formed according to any of the methods of FIGS. 1-3, according toan embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

A new form of carbon, called Q-carbon, was recently discovered. Q-carbonis a carbon ceramic that contains a fixed amount of the SP3 form ofcarbon (hereinafter, “SP3 carbon”) and a fixed amount of the SP2 form ofcarbon (hereinafter, “SP2 carbon”). Q-carbon may be produced in limitedquantities from laser irradiation of carbon films.

There are several drawbacks of using laser irradiation of carbon. First,laser irradiation of carbon does not allow exploration of the fullhybridization of carbon ceramics (SP1, SP2, and SP3 carbon). That is,the result will be Q-carbon, which does not include the SP1 form ofcarbon. Second, laser irradiation of carbon will always produceapproximately the same fixed percentage of SP2 carbon and SP3 carbon.Laser irradiation therefore does not provide the ability to tailor thepercentages of SP1, SP2, and SP3 carbon in the final ceramic. Becausethe final ceramic will always have a fixed percentage of SP2 and SP3carbon, the final ceramic will always have the same properties (e.g.,thermal conductivity, electrical conductivity, ferromagnetism, etc.).Third, laser irradiation of carbon produces a thin film or powder thatis not workable or produced in sufficient quantities to make largeitems, such as plates needed for transformers.

Accordingly, aspects of the present disclosure include a method that, inone embodiment, includes producing a mixed feedstock of at least threehalogenated monomer feedstocks. A first of the at least threehalogenated monomer feedstocks includes an SP3 carbon, a second of theat least three halogenated monomer feedstocks includes an SP2 carbon,and a third of the at least three halogenated monomer feedstocksincludes at least two SP3 carbons. The method further includes producinga polyorbital-hybrid pre-ceramic polymer comprising the SP1 carbons, theSP2 carbon, and the SP3 carbon. The polyorbital-hybrid pre-ceramicpolymer is produced by reducing the mixed feedstock such that a halogenatom is removed from the mixed feedstock. The method also includesfabricating the polyorbital-hybrid pre-ceramic polymer into a greenwareform and producing a polyorbital-hybrid ceramic carbon comprising theSP1 carbons, the SP2 carbon, and the SP3 carbon. The polyorbital-hybridceramic carbon is produced by thermolyzing the polyorbital pre-ceramicpolymer.

The present disclosure may provide numerous advantages. For example, themethod of the present disclosure may allow for exploration of the entireorbital hybridization space of SP1 carbon, SP2 carbon, and SP3 carbonceramics. As another example, the method may allow for tailoring of theamounts of SP1 carbon, SP2 carbon, and SP3 carbon in the final ceramic.As yet another example, the method may produce pre-ceramic polymers thatare workable materials. These workable materials can then be, forexample, dissolved, sprayed, molded, shaped, cast as films, oradditively deposited and built up to produce a greenware item. Becauseof the workability of the materials, the disclosure may provide atechnical advantage of being able to use a tailorable polyhybrid-orbitalceramic to manufacture products that have previously been unable to bemade using Q-carbon, such as the plates of a transformer or electricmotor stator and rotor plates.

Other technical advantages will be readily apparent to one skilled inthe art from the following figures, descriptions, and claims. Moreover,while specific advantages have been enumerated above, variousembodiments may include all, some, or none of the enumerated advantages.

Additional details are discussed in FIGS. 1 through 4. FIG. 1illustrates an example method of manufacturing a tailorablepolyorbital-hybrid ceramic carbon 130, FIG. 2 shows an example method ofmanufacturing a tailorable polyorbital-hybrid ceramic silicon 230, andFIG. 3 shows an example method of manufacturing a tailorablepolyorbital-hybrid ceramic silicon carbide 330. FIG. 4 illustrates anexample polyorbital-hybrid ceramic stator 405 formed according to any ofthe methods of FIGS. 1-3.

FIG. 1 is a diagram illustrating an example method of manufacturing atailorable polyorbital-hybrid ceramic carbon 130, according to anembodiment of the present disclosure. The method of manufacturing atailorable polyorbital-hybrid ceramic carbon 130 illustrated in FIG. 1includes four different steps in an embodiment. Each step will bediscussed below.

At step one, three halogenated monomer feedstocks are mixed together toproduce mixed feedstock 105 in an embodiment. Many methods of mixingfeedstocks may be used to produce mixed feedstock 105. In an embodiment,mixed feedstock 105 may be produced by adding the halogenated monomerfeedstocks to a reaction chamber.

Mixed feedstock 105 may include first halogenated monomer feedstock 110,second halogenated monomer feedstock 115, and third halogenated monomerfeedstock 120 in an embodiment. Mixed feedstock 105 may includerespective percentages of first halogenated monomer feedstock 110,second halogenated monomer feedstock 115, and third halogenated monomerfeedstock 120 in an embodiment. Mixed feedstock 105 may include a firstpercentage of SP1 carbon, a second percentage of SP2 carbon, and a thirdpercentage of SP3 carbon. By varying the percentages of each of thefeedstocks, polyorbital-hybrid pre-ceramic polymer 125 andpolyorbital-hybrid ceramic carbon 130 may have different percentages ofSP1 carbon, SP2 carbon, and SP3 carbon. For example, if apolyorbital-hybrid ceramic carbon 130 with an increased amount of SP1carbon is desired, then mixed feedstock 105 may be comprised of anincreased amount of third halogenated monomer feedstock 120, whichcontributes SP1 carbon to the resulting polyorbital-hybrid ceramiccarbon 130. The percentages of SP1 carbon, SP2 carbon, and SP3 carbon inmixed feedstock 105 may be approximately equal to the percentages of SP1carbon, SP2 carbon, and SP3 carbon in polyorbital-hybrid pre-ceramicpolymer 125 and polyorbital-hybrid ceramic carbon 130. These tailorablepercentages may provide polyorbital-hybrid pre-ceramic polymer 125 andpolyorbital-hybrid ceramic carbon 130 with varying properties, such asincreased or decreased ferromagnetism, electrical conductivity,hardness, thermal conductivity, etc.

First halogenated monomer feedstock 110 may be any monomer feedstockthat has halogen and can contribute one or more SP3 carbon atoms. Forexample, first halogenated monomer feedstock 120 may be chloroform.Chloroform has one carbon atom in SP3 configuration. SP3 configurationrefers to carbon in the sp³ orbital hybridization configuration. Anyamount of first halogenated monomer feedstock 110 may be used in mixedfeedstock 105.

Second halogenated monomer feedstock 115 may be any monomer feedstockthat has halogen and can contribute one or more SP2 carbon atoms. Forexample, second halogenated monomer feedstock 115 may be3,3,3-trichloropropene. 3,3,3-trichloropropene has two carbon atoms inan SP2 configuration. SP2 configuration refers to carbon in the sp²orbital hybridization configuration. Any amount of second halogenatedmonomer feedstock 115 may be used in mixed feedstock 105.

Third halogenated monomer feedstock 120 may be any monomer feedstockthat has halogen and can contribute two or more SP1 carbon atoms. Forexample, third halogenated monomer feedstock 120 may be propargyltrichloride. Propargyl trichloride has two carbon atoms in an SP1configuration. SP1 configuration refers to carbon in the sp¹ orbitalhybridization configuration. Any amount of third halogenated monomerfeedstock 120 may be used in mixed feedstock 105.

In some embodiments, an additional feedstock may be added to mixedfeedstock 105 to accomplish doping using p-type doping or n-type doping.For example, mixed feedstock 105 may include a feedstock that includes aGroup III p-type donor, such as, for example, boron trichloride. In thatexample, a Group III p-type donor may facilitate a p-type doping ofpolyorbital-hybrid ceramic carbon 130. As another example, mixedfeedstock 105 may include a Group IV n-type donor, such as, for example,phosphorus trichloride. In that example, a Group IV n-type donor mayfacilitate an n-type doping of polyorbital-hybrid ceramic carbon 130.One advantage that p-type or n-type doping may provide is thatpolyorbital-hybrid ceramic carbon 130 may be a p-type material or ann-type material that can be used to fabricate a p-type or an n-typesemiconductor.

At step 2, polyorbital-hybrid pre-ceramic polymer 125 may be produced inan embodiment. Polyorbital-hybrid pre-ceramic polymer 125 may beproduced by reducing mixed feedstock 105 such that one or more halogenatoms are removed from mixed feedstock 105 in an embodiment. Forexample, if chloroform is used as first halogenated monomer feedstock110, reducing mixed feedstock 105 may remove at least one chlorine atomfrom mixed feedstock 105. In some embodiments, reduction of mixedfeedstock 105 may result in removal of all halogen atoms from mixedfeedstock 105. In an embodiment, polyorbital-hybrid pre-ceramic polymer125 having a random sp³ backbone of sp³ carbon may be obtained. Step 2contemplates many different methods of reduction, including, forexample, electrolysis, a solvated electron method, a sodium-potassiumeutectic reduction, or a mechano-chemical reduction. Polyorbital-hybridpre-ceramic polymer 125 may include two or more SP1 carbon atomscontributed by third halogenated monomer feedstock 120, an SP2 carboncontributed by second halogenated monomer feedstock 115, and an SP3carbon contributed by first halogenated monomer feedstock 110.Polyorbital-hybrid pre-ceramic polymer 125 may bepoly(propargyl-co-propyl-co-hydrido-carbyne) in an embodiment.Polyorbital-hybrid pre-ceramic polymer 125 may be produced without usinga laser in an embodiment.

At step 3, polyorbital-hybrid pre-ceramic polymer may be fabricated intogreenware form 127 in an embodiment. Fabrication into greenware form 127may be done using any method of fabrication, such as, for example,spraying, molding, shaping, casting, or additively depositing andbuilding up. Greenware form 127 may be fabricated into any form, suchas, for example, a transformer plate, a transformer, a stator or rotorplate, an electric motor, a semiconductor, etc.

At step 4, polyorbital-hybrid ceramic carbon 130 may be produced in anembodiment. Polyorbital-hybrid ceramic carbon 130 may be produced bythermolyzing polyorbital-hybrid pre-ceramic polymer 125 in anembodiment. For example, polyorbital-hybrid pre-ceramic polymer 125 maybe broken down through heating polyorbital-hybrid pre-ceramic polymer125. In an embodiment, thermolysis may occur within a temperature rangeof 100 degrees Celsius to 900 degrees Celsuis. Thermolysis may removehyrodgen from polyorbital-hybrid pre-ceramic polymer 125. In someembodiments, thermolysis may occur in the absence of an oxidizer, suchas, for example, air, oxygen, or a halogen. Thermolysis may also be doneusing an inert atmosphere, such as, for example, using a noble gas(e.g., argon, helium, neon, krypton, or xenon) or nitrogen.

Polyorbital-hybrid ceramic carbon 130 may include the SP1 carbonsdonated from third halogenated monomer feedstock 120, the SP2 carbondonated from second halogenated monomer feedstock 115, and the SP3carbon donated from first halogenated monomer feedstock 110 in anembodiment. Polyorbital-hybrid ceramic carbon 130 may containapproximately the same percentages of SP1 carbon, SP2 carbon, and SP3carbon as contained in mixed feedstock 105 in an embodiment.Polyorbital-hybrid ceramic carbon 130 may therefore contain all threehybrid orbitals of carbon—SP1, SP2, and SP3. These percentages of SP1carbon, SP2 carbon, and SP3 carbon may change depending on the amount ofeach feedstock in an embodiment. As a result, polyorbital-hybrid ceramiccarbon 130 may have varying properties, such as increased or decreasedferromagnetism, electrical conductivity, hardness, thermal conductivity,etc. depending on the tailorable percentages of SP1 carbon, SP2 carbon,and SP3 carbon contained in mixed feedstock 105. Polyorbital-hybridceramic carbon 130 may be metal-free in an embodiment, which may reducethe weight of the application in which the polyorbital-hybrid ceramiccarbon 130 is used.

As an example embodiment of operation, mixed feedstock 105 may beproduced by mixing first halogenated monomer feedstock 110, secondhalogenated monomer feedstock 115, and third halogenated monomerfeedstock 120 in a reaction chamber. Mixed feedstock 105 may be reducedto remove one or more halogen atoms to form polyorbital-hybridpre-ceramic polymer 125. Polyorbital-hybrid pre-ceramic polymer 125 maybe fabricated into greenware form 127. Polyorbital-hybrid ceramic carbon130 may then be produced by thermolysis of polyorbital-hybridpre-ceramic polymer 125.

FIG. 2 is a diagram illustrating an example method of manufacturing atailorable polyorbital-hybrid ceramic silicon 230, according to anembodiment of the present disclosure.

The method of manufacturing a tailorable polyorbital-hybrid ceramicsilicon 230 illustrated in FIG. 2 includes four different steps in anembodiment. Each step will be discussed below.

At step one, three halogenated monomer feedstocks are mixed together toproduce mixed feedstock 205 in an embodiment. Many methods of mixingfeedstocks may be used to produce mixed feedstock 205. In an embodiment,mixed feedstock 205 may be produced by adding the halogenated monomerfeedstocks to a reaction chamber.

Mixed feedstock 205 may include first halogenated monomer feedstock 210,second halogenated monomer feedstock 215, and third halogenated monomerfeedstock 220 in an embodiment. Mixed feedstock 205 may includerespective percentages of first halogenated monomer feedstock 210,second halogenated monomer feedstock 215, and third halogenated monomerfeedstock 220 in an embodiment. For example, mixed feedstock 205 mayinclude a first percentage of SP1 silicon, a second percentage of SP2silicon, and a third percentage of SP3 silicon. By varying thepercentages of each of the feedstocks, polyorbital-hybrid pre-ceramicpolymer 225 and polyorbital-hybrid ceramic silicon 230 may havedifferent percentages of SP1 silicon, SP2 silicon, and SP3 silicon. Forexample, if a polyorbital-hybrid ceramic silicon 230 with an increasedamount of SP1 silicon is desired, then mixed feedstock 205 may becomprised of an increased amount of third halogenated monomer feedstock220, which contributes SP1 silicon to the resulting polyorbital-hybridceramic silicon 230. The percentages of SP1 silicon, SP2 silicon, andSP3 silicon in mixed feedstock 205 may be approximately equal to thepercentages of SP1 silicon, SP2 silicon, and SP3 silicon inpolyorbital-hybrid pre-ceramic polymer 225 and polyorbital-hybridceramic silicon 230. These tailorable percentages may providepolyorbital-hybrid pre-ceramic polymer 225 and polyorbital-hybridceramic silicon 230 with varying properties, such as increased ordecreased ferromagnetism, electrical conductivity, hardness, thermalconductivity, etc.

First halogenated monomer feedstock 210 may be any monomer feedstockthat has halogen and can contribute one or more SP3 silicon atoms. Forexample, first halogenated monomer feedstock 210 may be trichlorosilane.Trichlorosilane has one silicon atom in an SP3 configuration. SP3configuration refers to silicon in the sp³ orbital hybridizationconfiguration. Any amount of first halogenated monomer feedstock 210 maybe used in mixed feedstock 205.

Second halogenated monomer feedstock 215 may be any monomer feedstockthat has halogen and can contribute one or more SP2 silicon atoms. Forexample, second halogenated monomer feedstock 215 may betrichloro(disilene)silane. Trichloro(disilene)silane has two siliconatoms in an SP2 configuration. SP2 configuration refers to silicon inthe sp² orbital hybridization configuration. Any amount of secondhalogenated monomer feedstock 215 may be used in mixed feedstock 205.

Third halogenated monomer feedstock 220 may be any monomer feedstockthat has halogen and can contribute one or more SP1 silicon atoms. Forexample, third halogenated monomer feedstock 220 may betrichloro(disilyne)silane. Trichloro(disilyne)silane has two siliconatoms in SP1 configuration. SP1 configuration refers to silicon in thesp¹ orbital hybridization configuration. Any amount of third halogenatedmonomer feedstock 220 may be used in mixed feedstock 205.

In some embodiments, an additional feedstock may be added to mixedfeedstock 205 to accomplish doping using p-type doping or n-type doping.For example, mixed feedstock 205 may include a feedstock that includes aGroup III p-type donor, such as, for example, boron trichloride. In thatexample, a Group III p-type donor may facilitate a p-type doping ofpolyorbital-hybrid ceramic silicon 230. As another example, mixedfeedstock 205 may include a Group IV n-type donor, such as, for example,phosphorus trichloride. In that example, a Group IV n-type donor mayfacilitate an n-type doping of polyorbital-hybrid ceramic silicon 230.One advantage that p-type or n-type doping may provide is thatpolyorbital-hybrid ceramic silicon 230 may be a p-type material or ann-type material that can be used to fabricate a p-type or an n-typesemiconductor.

At step 2, polyorbital-hybrid pre-ceramic polymer 225 may be produced inan embodiment. Polyorbital-hybrid pre-ceramic polymer 225 may beproduced by reducing mixed feedstock 205 such that at least one halogenatom is removed from mixed feedstock 205 in an embodiment. For example,if trichloro(disilyne)silane is used as third halogenated monomerfeedstock 220, reducing mixed feedstock 205 may remove at least onechlorine atom from mixed feedstock 205. In some embodiments, reductionof mixed feedstock 205 may result in removal of all halogen atoms frommixed feedstock 205. In an embodiment, polyorbital-hybrid pre-ceramicpolymer 125 having a random sp³ backbone of sp³ silicon may be obtained.Step 2 contemplates many different methods of reduction, including, forexample, electrolysis, a solvated electron method, a sodium-potassium(NaK) eutectic reduction, or a mechano-chemical reduction.Polyorbital-hybrid pre-ceramic polymer 225 may include one or more SP3silicon atoms contributed by first halogenated monomer feedstock 210, anSP2 silicon contributed by second halogenated monomer feedstock 215, andan SP1 silicon contributed by third halogenated monomer feedstock 220.Polyorbital-hybrid pre-ceramic polymer 225 may bepoly(co-silyne-co-silene-co-hydrido-silyne) in an embodiment.Polyorbital-hybrid pre-ceramic polymer 225 may be produced without usinga laser in an embodiment. At step 3, polyorbital-hybrid pre-ceramicpolymer 225 may be fabricated into greenware form 227 in an embodiment.Fabrication into greenware form 227 may be done using any method offabrication, such as, for example, spraying, molding, shaping, casting,or additively depositing and building up. Greenware form 227 may befabricated into any form, such as, for example, a transformer plate, atransformer, a stator or rotor plate, an electric motor, asemiconductor, etc.

At step 4, polyorbital-hybrid ceramic silicon 230 may be produced in anembodiment. Polyorbital-hybrid ceramic silicon 230 may be produced bythermolyzing polyorbital-hybrid pre-ceramic polymer 225 in anembodiment. For example, polyorbital-hybrid pre-ceramic polymer 225 maybe broken down through heating polyorbital-hybrid pre-ceramic polymer225. In an embodiment, thermolysis may occur within a temperature rangeof 100 degrees Celsius to 900 degrees Celsuis.

Thermolysis may remove hyrodgen from polyorbital-hybrid pre-ceramicpolymer 225. In some embodiments, thermolysis may occur in the absenceof an oxidizer, such as, for example, air, oxygen, or chlorine.Thermolysis may also be done using an inert atmosphere, such as, forexample, using a noble gas (e.g., argon, helium, neon, krypton, orxenon) or nitrogen.

Polyorbital-hybrid ceramic silicon 230 may include the SP3 silicondonated from first halogenated monomer feedstock 210, the SP2 silicondonated from second halogenated monomer feedstock 215, and the SP1silicon donated from third halogenated monomer feedstock 220 in anembodiment. Polyorbital-hybrid ceramic silicon 230 may containapproximately the same percentages of SP1 silicon, SP2 silicon, and SP3silicon as contained in mixed feedstock 205 in an embodiment. Thesepercentages of SP1 silicon, SP2 silicon, and SP3 silicon may changedepending on the amount of each feedstock in an embodiment. As a result,polyorbital-hybrid ceramic silicon 230 may have varying properties, suchas increased or decreased ferromagnetism, electrical conductivity,hardness, etc. depending on the tailorable percentages of SP1 silicon,SP2 silicon, and SP3 silicon contained in mixed feedstock 205.Polyorbital-hybrid ceramic silicon 230 may be metal-free in anembodiment, which may reduce the weight of the application in which thepolyorbital-hybrid ceramic silicon 230 is used.

As an example embodiment of operation, mixed feedstock 205 may beproduced by mixing first halogenated monomer feedstock 210, secondhalogenated monomer feedstock 215, and third halogenated monomerfeedstock 220 in a reaction chamber. Mixed feedstock 205 may be reducedto remove at least one halogen atom to form polyorbital-hybridpre-ceramic polymer 225. Polyorbital-hybrid pre-ceramic polymer 225 maybe fabricated into greenware form 227. Polyorbital-hybrid ceramicsilicon 230 may then be produced by thermolysis of polyorbital-hybridpre-ceramic polymer 225.

FIG. 3 is a diagram illustrating an example method of manufacturing atailorable polyorbital-hybrid ceramic silicon. carbide 330. The methodof manufacturing a tailorable polyorbital-hybrid ceramic silicon carbide330 illustrated in FIG. 3 includes four different steps in anembodiment. Each step will be discussed below.

At step one, four halogenated monomer feedstocks are mixed together toproduce mixed feedstock 305 in an embodiment. Many methods of mixingfeedstocks may be used to produce mixed feedstock 305. In an embodiment,mixed feedstock 305 may be produced by adding the halogenated monomerfeedstock to a reaction chamber.

Mixed feedstock 305 may include first halogenated monomer feedstock 310,second halogenated monomer feedstock 315, third halogenated monomerfeedstock 320, and fourth halogenated monomer feedstock 321 in anembodiment. Mixed feedstock 305 may include respective percentages offirst halogenated monomer feedstock 310, second halogenated monomerfeedstock 315, third halogenated monomer feedstock 320, and fourthhalogenated monomer feedstock 321 in an embodiment. Mixed feedstock 305may include a first percentage of SP1 silicon or SP1 carbon, a secondpercentage of SP2 silicon or SP2 carbon, and a third percentage of SP3silicon or SP3 carbon. By varying the percentages of each of thefeedstocks, polyorbital-hybrid pre-ceramic polymer 325 andpolyorbital-hybrid ceramic silicon carbide 330 may have differentpercentages of SP1 silicon or SP1 carbon, SP2 silicon or SP2 carbon, andSP3 silicon or SP3 carbon. For example, if a polyorbital-hybrid ceramicsilicon carbide 330 with an increased amount of SP1 silicon is desired,then mixed feedstock 305 may be comprised of an increased amount offirst halogenated monomer feedstock 310, which contributes SP1 siliconto the resulting polyorbital-hybrid ceramic silicon carbide 330. Thepercentages of SP1 silicon, SP2 silicon, and SP3 silicon in mixedfeedstock 305 may be approximately equal to the percentages of SP1silicon, SP2 silicon, and SP3 silicon in polyorbital-hybrid pre-ceramicpolymer 325 and polyorbital-hybrid ceramic silicon carbide 330. Thesetailorable percentages may provide polyorbital-hybrid pre-ceramicpolymer 325 and polyorbital-hybrid ceramic silicon carbide 330 withvarying properties, such as increased or decreased ferromagnetism,electrical conductivity, hardness, etc.

First halogenated monomer feedstock 310 may be any monomer feedstockthat has halogen, and can contribute one or more SP3 silicon atoms. Forexample, first halogenated monomer feedstock 310 may includetrichlorosilane (contributes one or more SP3 silicon atoms).Trichlorosilane has one silicon atom in an SP3 configuration. Any amountof first halogenated monomer feedstock 310 may be used in mixedfeedstock 305.

Second halogenated monomer feedstock 315 may be any monomer feedstockthat has halogen and can contribute one or more SP3 silicon atoms andone of one or more SP2 silicon atoms or SP2 carbon atoms. For example,second halogenated monomer feedstock 315 may be vinyltrichlorosilane.Vinyltrichlorosilane has one silicon atom in an SP3 configuration andtwo carbon atoms in SP2 configuration. Any amount of second halogenatedmonomer feedstock 315 may be used in mixed feedstock 305.

Third halogenated monomer feedstock 320 may be any monomer feedstockthat has halogen and can contribute one or more SP3 silicon atoms andone of one or more SP1 silicon atoms or two or more SP1 carbon atoms.For example, third halogenated monomer feedstock 320 may bepropargyltrichlorosilane. Propargyltrichlorosilane has one silicon atomin SP3 configuration and two SP1 carbon atoms. Any amount of thirdhalogenated monomer feedstock 320 may be used in mixed feedstock 305.

Fourth halogenated monomer feedstock 321 may be any monomer feedstockthat has halogen, and can contribute one or more SP3 carbon atoms. Forexample, first halogenated monomer feedstock 310 may include chloroform(contributes one or more SP3 carbon atoms). Chloroform has one carbonatom in an SP3 configuration. Any amount of first halogenated monomerfeedstock 310 may be used in mixed feedstock 305.

In some embodiments, an additional feedstock may be added to mixedfeedstock 305 to accomplish doping using p-type doping or n-type doping.For example, mixed feedstock 305 may include a feedstock that includes aGroup III p-type donor, such as, for example, boron trichloride. In thatexample, a Group III p-type donor may facilitate a p-type doping ofpolyorbital-hybrid ceramic silicon 330. As another example, mixedfeedstock 305 may include a Group IV n-type donor, such as, for example,phosphorus trichloride. In that example, a Group IV n-type donor mayfacilitate an n-type doping of polyorbital-hybrid ceramic silicon 330.One advantage that p-type or n-type doping may provide is thatpolyorbital-hybrid ceramic silicon 330 may be a p-type material or ann-type material that can be used to fabricate a p-type or an n-typesemiconductor.

At step 2, polyorbital-hybrid pre-ceramic polymer 325 may be produced inan embodiment. Polyorbital-hybrid pre-ceramic polymer 325 may beproduced by reducing mixed feedstock 305 such that at least one halogenatom is removed from mixed feedstock 305 in an embodiment. For example,if propargyltrichlorosilane is used as third halogenated monomerfeedstock 320, reducing mixed feedstock 305 may remove at least onechlorine atom from mixed feedstock 305. In some embodiments, reductionof mixed feedstock 305 may result in removal of all halogen atoms frommixed feedstock 305. In an embodiment, polyorbital-hybrid pre-ceramicpolymer 125 having a random sp³ backbone of both sp³ carbon and sp³silicon may be obtained. Step 2 contemplates many different methods ofreduction, including, for example, electrolysis, a solvated electronmethod, a sodium-potassium reduction, or a mechano-chemical reduction.Polyorbital-hybrid pre-ceramic polymer 325 may include at least one ofthe first SP1 silicon, the second SP1 silicon, or the third SP1 siliconin an embodiment. Polyorbital-hybrid pre-ceramic polymer 325 may furtherinclude two or more SP1 carbons, an SP2 carbon, and/or an SP3 carbon inan embodiment. Polyorbital-hybrid pre-ceramic polymer 325 may bepoly(co-propargyl-co-vinyl-co-hydrido-carbyne-silyne) in an embodiment.Polyorbital-hybrid pre-ceramic polymer 325 may be produced without usinga laser in an embodiment.

At step 3, polyorbital-hybrid pre-ceramic polymer 325 may be fabricatedinto greenware form 327 in an embodiment. Fabrication into greenwareform 327 may be done using any method of fabrication, such as, forexample, spraying, molding, shaping, casting, or additively depositingand building up. Greenware form 327 may be fabricated into any form,such as, for example, a transformer plate, a transformer, a stator orrotor plate, an electric motor, a semiconductor, etc.

At step 4, polyorbital-hybrid ceramic silicon carbide 330 may beproduced in an embodiment. Polyorbital-hybrid ceramic silicon carbide330 may be produced by thermolyzing polyorbital-hybrid pre-ceramicpolymer 325 in an embodiment. For example, polyorbital-hybridpre-ceramic polymer 325 may be broken down through heatingpolyorbital-hybrid pre-ceramic polymer 325. In an embodiment,thermolysis may occur within a temperature range of 100 degrees Celsiusto 900 degrees Celsuis. Thermolysis may remove hydrogen frompolyorbital-hybrid pre-ceramic polymer 325. In some embodiments,thermolysis may occur in the absence of an oxidizer, such as, forexample, air, oxygen, or chlorine. Thermolysis may also be done using aninert atmosphere, such as, for example, using a noble gas (e.g., argon,helium, neon, xenon, or nitrogen).

Polyorbital-hybrid ceramic silicon carbide 330 may include the SP3silicon donated from first halogenated monomer feedstock 310 or the SP3carbon donated from fourth halogenated monomer feedstock 321, the SP2carbon and/or the SP2 silicon donated from second halogenated monomerfeedstock 315, the SP1 silicon and/or the SP1 carbons donated from thirdhalogenated monomer feedstock 320 in an embodiment. Polyorbital-hybridceramic silicon carbide 330 may contain approximately the samepercentages of SP1 silicon carbide, SP2 silicon carbide, and SP3 siliconcarbide as contained in mixed feedstock 305 in an embodiment. Thesepercentages of SP1 silicon carbide, SP2 silicon carbide, and SP3 siliconcarbide may change depending on the amount of each feedstock in anembodiment. As a result, polyorbital-hybrid ceramic silicon carbide 330may have varying properties, such as increased or decreasedferromagnetism, electrical conductivity, hardness, etc. depending on thetailorable percentages of SP1 silicon carbide, SP2 silicon carbide, andSP3 silicon carbide contained in mixed feedstock 305. Polyorbital-hybridceramic silicon carbide 330 may be metal-free in an embodiment, whichmay reduce the weight of the application in which the polyorbital-hybridceramic silicon carbide 330 is used.

As an example embodiment of operation, mixed feedstock 305 may beproduced by mixing first halogenated monomer feedstock 310, secondhalogenated monomer feedstock 315, third halogenated monomer feedstock320, and fourth halogenated monomer feedstock 321 in a reaction chamber.Mixed feedstock 305 may be reduced to remove at least one halogen atomto form polyorbital-hybrid pre-ceramic polymer 325. Polyorbital-hybridpre-ceramic polymer 325 may be fabricated into greenware form 327.Polyorbital-hybrid ceramic silicon carbide 330 may then be produced bythermolysis of polyorbital-hybrid pre-ceramic polymer 325.

FIG. 4 is an exploded view of an example polyorbital-hybrid ceramicstator 405 formed according to any of the methods of FIGS. 1-3,according to an embodiment of the present disclosure. As noted above,the methods of FIGS. 1-3 may include fabrication of a poly-orbitalpre-ceramic polymer into a greenware form, which is then thermolyzed toproduce a polyorbital-hybrid ceramic. In an embodiment, thepolyorbital-hybrid ceramic may be polyorbital-hybrid ceramic stator 405.Such a polyorbital-hybrid ceramic stator 405 may be used in, forexample, an electric motor. Although illustrated as a stator, themethods of FIGS. 1-3 may be used to produce other products, such as arotor. Polyorbital-hybrid ceramic stator 405 may be metal-free and thuslightweight in an embodiment. Polyorbital-hybrid ceramic stator 405 maybe formed by, for example, additive manufacturing (e.g., building orprinting layer by layer). Polyorbital-hybrid ceramic stator 405 may havedifferent tailored polyorbital-hybrid ceramics, thereby producingcomponents that have varying properties (e.g., ferromagnetism,conductivity, insulation, etc.). In the example embodiment of FIG. 4,polyorbital-hybrid ceramic stator 405 includes polyorbital-hybridceramic stator plate 410, polyorbital-hybrid ceramic insulator plate420, and polyorbital-hybrid ceramic wire 430.

Polyorbital-hybrid ceramic stator plate 410 may be a stator producedaccording to any of the methods of FIGS. 1-3. For example,polyorbital-hybrid ceramic stator plate 410 may be produced according tothe method of FIG. 1. In that example, polyorbital-hybrid ceramic statorplate 410 may be a ferromagnetic carbon ceramic. As explained throughoutthis disclosure, the percentages of SP1, SP2, and SP3 carbon may betailored according to the desired properties of the product. In thisexample, polyorbital-hybrid ceramic stator plate 410 may have 2% SP1carbon, 15% SP2 carbon, and 83% SP3 carbon. Other percentages may beused.

Polyorbital-hybrid ceramic insulator plate 420 may be an insulator plateproduced according to any of the methods of FIGS. 1-3. For example,polyorbital-hybrid ceramic insulator plate 420 may be produced accordingto the method of FIG. 1. In that example, polyorbital-hybrid ceramicinsulator plate 420 may be an electrically insulative, thermallyconductive carbon ceramic. As explained throughout this disclosure, thepercentages of SP1, SP2, and SP3 carbon may be tailored according to thedesired properties of the product. In this example, polyorbital-hybridceramic insulator plate 420 may have 2% SP1 carbon, 2% SP2 carbon, and96% SP3 carbon. Other percentages may be used.

Polyorbital-hybrid ceramic wire 430 may be a wire produced according toany of the methods of FIGS. 1-3. For example, polyorbital-hybrid ceramicwire 430 may be produced according to the method of FIG. 1. In thatexample, polyorbital-hybrid ceramic wire 430 may be an electricallyconductive carbon ceramic. As explained throughout this disclosure, thepercentages of SP1, SP2, and SP3 carbon may be tailored according to thedesired properties of the product. In this example, polyorbital-hybridceramic wire 430 may have 75% SP1 carbon, 15% SP2 carbon, and 10% SP3carbon to achieve electrical conductivity. Other percentages may beused. Polyorbital-hybrid ceramic wire 430 may be insulated by apolyorbital-hybrid ceramic insulator, such as the same material used toform polyorbital-hybrid ceramic insulator plate 420 in an embodiment.

Other technical advantages will be readily apparent to one skilled inthe art from the following figures, descriptions, and claims. Moreover,while specific advantages have been enumerated above, variousembodiments may include all, some, or none of the enumerated advantages.

Although the present disclosure has been described with severalembodiments, a myriad of changes, variations, alterations,transformations, and modifications may be suggested to one skilled inthe art, and it is intended that the present disclosure encompass suchchanges, variations, alterations, transformations, and modifications asfall within the scope of the appended claims.

The invention claimed is:
 1. A method, comprising: producing a mixedfeedstock of at least three halogenated monomer feedstocks, wherein afirst of the at least three halogenated monomer feedstocks includes anSP3 carbon, a second of the at least three halogenated monomerfeedstocks includes an SP2 carbon, and a third of the at least threehalogenated monomer feedstocks includes at least two SP1 carbons;producing a polyorbital-hybrid pre-ceramic polymer comprising the SP1carbons, the SP2 carbon, and the SP3 carbon, wherein thepolyorbital-hybrid pre-ceramic polymer is produced by reducing the mixedfeedstock such that one or more halogen atoms are removed from the mixedfeedstock; fabricating the polyorbital-hybrid pre-ceramic polymer into agreenware form; and producing a polyorbital-hybrid ceramic carboncomprising the SP1 carbons, the SP2 carbon, and the SP3 carbon, whereinthe polyorbital-hybrid ceramic carbon is produced by thermolyzing thepolyorbital pre-ceramic polymer.
 2. The method of claim 1, wherein thefirst of the at least three halogenated monomer feedstocks compriseschloroform.
 3. The method of claim 1, wherein the second of the at leastthree halogenated monomer feedstocks comprises 3,3,3-trichloropropene.4. The method of claim 1, wherein the third of the at least threehalogenated monomer feedstocks comprises propargyl trichloride.
 5. Themethod of claim 1, wherein: the mixed feedstock comprises respectivefirst percentages of the SP1 carbons, the SP2 carbon, and the SP3carbon; the polyorbital-hybrid pre-ceramic polymer comprises respectivesecond percentages of the SP1 carbons, the SP2 carbon, and the SP3carbon; and the respective first percentages are approximately equal tothe respective second percentages.
 6. The method of claim 1, wherein thepolyorbital-hybrid preceramic polymer is thermolyzed within atemperature range of 100 degrees Celsius to 900 degrees Celsius.
 7. Themethod of claim 1, wherein the mixed feedstock further comprises one ofa Group III p-type donor or a Group IV n-type donor such that thepolyhybrid orbital ceramic carbon comprises a p-type doping or an n-typedoping.
 8. The method of claim 7, wherein the Group III p-type donorcomprises boron trichloride.
 9. The method of claim 7, wherein the GroupIV n-type donor comprises phosphorus trichloride.
 10. The method ofclaim 1, wherein the polyorbital-hybrid pre-ceramic polymer is producedwithout using a laser.